working with hybrid vehicles - scaniaedisp/bwm... · in case of fire in a hybrid vehicle, proceed...

02:70-01 Issue 01 en-G

Working with hybrid vehicles
General information on hybrid vehicles and hybrid systems
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General information on hybrid vehicles and hybrid systemsScania’s hybrid vehicles are parallel hybrids consisting of a combustion engine and an electric motor.

Parallel hybrid vehicles can be powered by both the electric motor and the combus-tion engine, either together or separately. For normal driving the electric motor and combustion engine power the vehicle in a way that maximizes efficiency and perfor-mance.

Hybrid vehicles have two electrical systems, one system with voltage class A (24 V) and another with voltage class B (650 V)1.

1. Definition according to ISO 6469-3

Voltage DC ACVoltage class A 0-60 V 0-30 V

Voltage class B 60-1,500 V 30-1,000 V

B 1 (15)© Scania CV AB 2016, Sweden

Hybrid system’s location and componentsWorking with hybrid vehicles

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Hybrid system’s location and componentsA. Hybrid power unit

1. Inverter

2. Coolant pump for coolant circuit for the inverter and direct current converter

3. Central electric unit for voltage class B

4. Direct current converter

5. Hybrid battery

6. Expansion tank for coolant circuit for the hybrid battery

7. Expansion tank for coolant circuit for the inverter and direct current converter

8. Electric heater

9. Control unit

10. Solenoid valve

11. Coolant pump for coolant circuit for the hybrid battery

12. Radiator for coolant circuit for the inverter and direct current converter

13. Radiator for coolant circuit for the hybrid battery

14. Fan

B. Gearbox

15. Electric motor

16. Cable harness for voltage class B

© Scania CV AB 2016, Sweden

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Hybrid system’s location and componentsWorking with hybrid vehicles

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Warning plate for voltage class B

The following components have voltage class B and are provided with warning plates for the voltage:

• Hybrid battery

• Central electric unit for voltage class B

• Direct current converter

• Electric heater

• Inverter

• Electric motor

Note:The hybrid system’s cable harness for voltage class B is orange.


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Hybrid system functionsWorking with hybrid vehicles

Hybrid system functionsThe hybrid battery supplies the hybrid system with electrical energy. It is connected to the electromagnetic electric motor via an inverter which supplies the electric motor with 3-phase alternating current by converting the hybrid battery’s voltage 650 V DC to 3-phase 400 V AC.

The following applies to the electromagnetic electric motor:

• it is located between the gearbox and the combustion engine

• it is used to power the vehicle but also as a generator to charge the hybrid battery

• it works as a generator when braking or when the combustion engine is running

• it produces 400 V AC which the inverter converts to 650 V DC for charging the hybrid battery

The direct current converter converts the hybrid battery’s voltage of 650 V to 24 V and supplies both the 24 V battery system and the vehicle’s electrical system with this voltage. In this way the direct current converter replaces the generator, which charges the 24 V system in vehicles that are not hybrids.


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Idle stop and start of the combustion engineWorking with hybrid vehicles

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Switch for idle stop and start.

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Warning plate stating that components can start to rotate automatically when idle stop and start is activated.

Idle stop and start of the combustion en-gineThe hybrid system has an idle stop and start function that switches off the combustion engine when the vehicle or help system does not need any engine power. The func-tion restarts the combustion engine when engine power is required.

There are two ways to deactivate idle stop and start:

• By switching off the vehicle with the starter key

• By pressing the switch for the function

When the indicator lamp in the switch is green, the function is activated. When the indicator lamp is out, the function is deactivated.

The combustion engine will be running when idle stop and start is deactivated by the switch.

WARNING!When idle stop and start is activated the combustion engine can restart automatically, which can cause the components to rotate. Do not leave the vehicle without having first switched off the combustion engine with the starter key or deactivated idle stop and start via the switch.

IMPORTANT!

The switch only switches off idle stop and start temporarily. The function is reacti-vated when the starter lock is deactivated and turned to the drive mode again.


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Risks related to the hybrid systemWorking with hybrid vehicles

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The control switch inside the hybrid power unit.

Risks related to the hybrid system

WARNING!Do not carry out any work on the hybrid installation or inside the hybrid power unit. Only open the inspection hatch for the hybrid power unit to access the control switch for disconnection of the hybrid system.

WARNING!The electric motor produces current when the combustion engine is in operation, or if it starts to rotate for any other reason, even if the hybrid system is otherwise dis-connected.


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Risks related to the hybrid systemWorking with hybrid vehicles

WARNING!The hybrid battery is sensitive to high temperatures and releases flammable gases at temperatures above 100°C.

• Never expose the hybrid battery to temperatures above 100°C.

• Never carry out hot work near the hybrid power unit.

The hybrid power unit protects the hybrid battery against external damage. Damage to the hybrid power unit can cause damage to the hybrid battery or overload it.

WARNING!A damaged hybrid battery can start to release vapours or a mist, which irritate the air-ways, membranes, eyes and skin. This can cause dizziness, sickness and headaches. The contents of the hybrid battery are highly flammable and corrosive to the skin in combination with dampness.


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Safety measures related to the hybrid systemWorking with hybrid vehicles

Safety measures related to the hybrid sys-temExtinguishing fireIn case of fire in a hybrid vehicle, proceed as follows:

• Use a fire extinguisher intended for electrical fires if there is a fire in the hybrid power unit.

• Follow the standard extinguishing procedures for vehicle fires if the hybrid power unit is intact and not on fire. Use a lot of water or foam to cool the hybrid power unit. If the hybrid power unit has been damaged, do not use water to extinguish the fire as this can initially make it worse.

Washing the vehicleDo not use a high pressure washer directly on the cooling system at the gearbox or to wash the hybrid power unit’s air intake and outlet, as this may damage the cooling functions of the hybrid system.


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The control switch.

Bodybuilding proceduresIMPORTANT!

Never use the control switch when the combustion engine is running, as this may damage the vehicle. Therefore, always switch off the combustion engine with the starter key before the hybrid battery is disconnected with the control switch.

WARNING!Contact a Scania workshop if error messages related to the hybrid system appear in the ICL (Instrument Cluster)1. The faults must be rectified before any work can be started on the bodywork.

IMPORTANT!

Contact a Scania workshop if any part of the hybrid installation gets damaged while building the bodywork.

The control switch is a battery master switch that disconnects the hybrid battery from the vehicle’s electrical system. The control switch is located under the inspection hatch of the hybrid power unit.

For all work with the bodywork, use the control switch to disconnect the hybrid bat-tery from the vehicle’s electrical system and switch off the hybrid system.

1. Instrument cluster


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Side skirt on the hybrid power unit.

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Inspection hatch.

Procedures prior to any bodybuilding1. Check that there are no error messages related to the hybrid system in the ICL. If

there are error messages in the ICL, contact a Scania workshop. The faults must be rectified before any work can be started on the bodywork.

2. Switch off the vehicle with the starter key.

3. Remove the side skirt from the hybrid power unit.

4. Remove the inspection hatch on the hybrid power unit to access the control switch.

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The hybrid system’s control switch.

5. Switch off the hybrid system using the hybrid system’s control switch.

6. Carry out the building of the bodywork.


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The hybrid system’s control switch.

Procedures after building the bodywork1. Start the hybrid system using the control switch.

2. Start the vehicle and let the engine run for at least 10 seconds to activate the hy-brid system.

3. Check that there are no error messages related to the hybrid system in the ICL. If there are error messages in the ICL, contact a Scania workshop. The faults must be rectified before any work can be started on the bodywork.

Continued on next page.


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Inspection hatch on the hybrid power unit.

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Side skirt on the hybrid power unit.

4. Fit the inspection hatch to the hybrid power unit.

5. Fit the side skirt.


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Chassis modifications on hybrid vehiclesWorking with hybrid vehicles

Chassis modifications on hybrid vehiclesWARNING!

Modifications to the hybrid installation are not permitted. It must not be moved, dis-mantled or changed in any way after delivery from the factory. The hybrid installa-tion includes all components presented earlier in this document and all electrical cables connected to these components.

WARNING!Drawing current from/connecting units to any part of the hybrid system is not per-mitted.

IMPORTANT!

All work with the hybrid installation may only be carried out by qualified personnel at Scania workshops. Contact a Scania workshop for more information.

When the power take-off is activated, the combustion engine will start automatically. The power take-off cannot be driven by the electric motor with the combustion en-gine switched off.

It is not possible to use power take-offs of the EK type or from the EG500 series on hybrid vehicles.

The direct current converter can supply 7.5 kW to the 24 V system. Do not connect any system that makes the total power in the 24 V system exceed 7.5 kW.


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Chassis modifications on hybrid vehiclesWorking with hybrid vehicles

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50 mm

25 mm

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Minimum distance permitted between the hybrid power unit and the bodywork.

REQUIREMENT!The following requirements apply to chassis modifications:

• Do not paint the orange-coloured cable harness for voltage class B.

• Fit components, electrical cables or bodywork in such a way that there is no risk of damaging electrical cables belonging to the hybrid installation.

• Do not block the hybrid power unit’s air intake or air outlet.

• Do not place any hot components or components that create great temperature in-crease behind the hybrid power unit, as this can impair the performance of the hy-brid power unit’s cooling system.

• Fit the bodywork and components at least 100 mm from the orange-coloured ca-ble harness for voltage class B. Make sure the new components and bodywork around the cable harness for voltage class B do not increase the temperature by more than 10°C. If the temperature increases by more than 10°C, the protective distance must be more than 100 mm.

• Fit the bodywork or components at least 20 mm above and at least 25 mm behind the hybrid power unit. Make sure there is at least 50 mm empty space above the inspection hatch. See illustration.

• It is not permitted to place anything in front of the hybrid power unit.


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working with hybrid vehicles - scaniaedisp/bwm... · in case of fire in a hybrid vehicle, proceed...

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